Section 6

Brake System
Overview The hybrid vehicle brake system includes both standard hydraulic
brakes and a unique regenerative braking system that uses the
vehicle’s momentum to recharge the battery. As soon as the accelerator
pedal is released, the HV ECU initiates regenerative braking. MG2 is
turned by the wheels and used as a generator to recharge the batteries.
During this phase of braking, the hydraulic brakes are not used. When
more rapid deceleration is required, the hydraulic brakes are activated
to provide additional stopping power. To increase energy efficiency the
system uses the regenerative brakes whenever possible. Selecting B"
on the shift lever will maximize regenerative efficiency and is useful for
controlling speeds downhill. In ‘B’ mode about 30% of the energy is
recovered.

If either the regenerative or hydraulic braking system fails, the

remaining system will still work. However, the brake pedal will be
harder to press and the stopping distance will be longer. In this
situation, the brake system warning light will illuminate.

The battery will accept charge up to an instantaneous rate of 20 to 21

NOTE KWH. Much of the energy from light braking at high speeds and
harder braking at lower speeds can be recovered. Excess energy over
the charging limits is wasted as heat in the brakes just as in other
cars. At this time there is no way for the customer to know the limit of
regenerative energy recovery.

Brake System
Components
(’01 -’03 Prius)

Figure 6.1 T072f601c

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Regenerative Regenerative brake cooperative control balances the brake force of the
Brake regenerative and hydraulic brakes to minimize the amount of kinetic
energy lost to heat and friction. It recovers the energy by converting it
Cooperative into electrical energy.
Control
To convert kinetic energy to electrical energy the system uses MG2 as a
generator. The drive axle and MG2 are joined mechanically. When the
drive wheels rotate MG2 it tends to resist the rotation of the wheels,
providing both electrical energy and the brake force needed to slow the
vehicle. The greater the battery charging amperage, the greater the
resistance.

On the ’04 & later Prius, the increased power output of MG2 provides
increased regenerative brake force. In addition, the distribution of the
brake force has been improved through the adoption of the
Electronically Controlled Brake (ECB) system, effectively increasing
the range of the regenerative brake. These attributes enhance the
system’s ability to recover electrical energy which contributes to fuel
economy.

Regenerative
Brake System

Figure 6.2 T072f602c

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Brake ECU In the ’01’03 Prius, the Brake ECU communicates with the HV ECU
(’01-’03 Prius) based on signals received from sensors. The controls include:
• Conventional brake control
• ABS with EBD control
• Regenerative brake cooperative control

Skid Control ECU In the ’04 & later Prius, brake control processing is moved to the Skid
(’04 & later Prius) Control ECU which maintains communication with the EPS ECU and
the HV ECU based on signals received from sensors. The controls
include:
• Conventional brake control
• ABS with EBD control
• Brake Assist
• Enhanced VSC
• Regenerative brake cooperative control

Enhanced VSC The Enhanced VSC system is available on the ’04 & later Prius. The
System following are two examples that can be considered as circumstances in
(’04 & later Prius) which tires exceed their lateral grip limit. The Enhanced VSC system
is designed to help control the vehicle behavior by controlling the
motive force and the brakes at each wheel when the vehicle is meets
one of these two conditions:
• When the front wheels lose grip in relation to the rear wheels (front
wheel skid tendency known as ‘understeer’)
• When the rear wheels lose grip in relation to the front wheels (rear
wheel skid tendency, or ‘oversteer’)

Enhanced VSC When the skid control ECU determines that the vehicle exhibits a
Operation tendency to understeer or oversteer, it decreases the engine output and
(’04 & later Prius) applies the brake of a front or rear wheel to control the vehicle’s yaw
moment. The basic operation of the Enhanced VSC is described below.
However, the control method differs depending on the vehicle’s
characteristics and driving conditions.

When the skid control ECU determines that there is a large front
wheel skid tendency, it counteracts in accordance with the extent of
that tendency. The skid control ECU controls the motive power output

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and applies the brakes of the front wheel of the outer circle in the turns
and rear wheels in order to restrain the front wheel skid tendency.

When the skid control ECU determines that there is a large rear wheel
skid tendency, it counteracts in accordance with the extent of that
tendency. It applies the brakes of the front wheel of the outer circle of
the turn and generates an outward moment of inertia in the vehicle, in
order to restrain the rear wheel tendency. Along with the reduction in
the vehicle speed caused by the braking force, the vehicle’s stability is
ensured. In some cases the skid control ECU applies the brake of the
rear wheels, as necessary.

Cooperative Enhanced VSC provides the steering assist to facilitate steering

Control with EPS operation for the driver depending on vehicle situations. This is
accomplished through coordination of cooperative control with EPS in
(’04 & later Prius)
addition to the general VSC control.

Cooperative
Control with EPS

Figure 6.3 T072f603c

Brake Pedal In the ’04 & later Prius, this sensor contains a contact variable resistor
Stroke Sensor and detects the extent of the brake pedal stroke and transmits it to the
skid control ECU.
(’04 & later Prius)

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To install a brake pedal stroke sensor, which is available as a service

SERVICE TIP part, perform the following procedures:
• The sensor lever is secured with a pin to 0" stroke. (Do not detach
the pin until the installation has been completed.)
• In this state, install the sensor on the brake pedal (in the OFF
state) on the vehicle.
• After completing the installation, firmly press the brake pedal once
to break off the pin that is securing the sensor in place.
• Make sure the broken pin does not remain in the sensor lever.

Stroke Simulator The stroke simulator is located between the master cylinder and the
brake actuator. It generates a pedal stroke in accordance with the
driver’s pedal effort during braking. Containing two types of coil
springs with different spring constants, the stroke simulator provides
pedal stroke characteristics in two stages in relation to the master
cylinder pressure.

Stroke Simulator

Figure 6.4 T072f604c

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Power Source In the ’04 & later Prius, the power source backup unit has been
Backup Unit adopted as an auxiliary power source in order to supply power to the
brake in a stable manner. This unit contains 28 capacitor cells, which
(’04 & later Prius)
store an electrical charge provided by the (12V) vehicle power supply.
When the voltage of the (12V) vehicle power supply drops, the electrical
charge stored in the capacitor cells is used as an auxiliary power
supply to the brake system. The electrical charge stored in the
capacitor cells becomes discharged when the HV system stops
operating after the power switch is turned OFF.

Power Source
Backup Unit

Figure 6.5 T072f605c

Fail-Safe If the ABS, Enhanced VSC or Brake Assist System malfunctions, the
Skid Control ECU disables that system but allows the other systems to
function normally.

DRC C1215/15, DTC C1215/15 may be detected when the ignition switch is ON, the
C1216/16 Linear voltage of terminal +BS in the brake ECU is 2.5V or less, and
continues for 0.5 seconds or more. It also may be detected while a
Solenoid Positive vehicle is driven at a speed 5mph or more, the voltage of terminal +BS
Voltage in the brake ECU is 9V or less and continues for 10 seconds or more.
Malfunction
DTC C1216/16 may be detected when the ignition switch is ON, the
voltage of the terminal +BS in the brake ECU is 17V or more, and
continues for 1.2 seconds or more. For both codes check the battery, the
charging system and the power source circuit.

The trouble areas for both codes may include the battery, the charging
system or the power source circuit.

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DTC C1259/59 If any trouble occurs in the HV control system, the ECU prohibits
Malfunction In Regenerative Braking System (RBS) control. If the conditions below
continue for 0.02 seconds DTC C1259/59 will set:
HV ECU
• The voltage of the terminal IG2 in the brake ECU is 10.5V or less
and continues for 1.5 seconds.
• Regenerative malfunction occurs on the HV ECU side.

This DTC is set with most HV ECU codes and is usually the lowest
NOTE priority when sent with other DTCs.

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